Jan Lasson Andreasen

Influence of Workpiece Surface Topography on the Mechanisms of Liquid Lubrication in Strip Drawing

The workpiece surface topography is an important factor controlling the mechanisms of lubrication in metal forming processes. In the present work, the microscopic lubrication mechanisms induced by lubricant trapped in pockets of the surface in strip drawing are studied. The experiments are performed with macroscopic model pockets in the surface studying the influence of the shape of the pockets on the lubrication mechanisms. A large radius of curvature on the rear edge and a small angle to the edge of the lubricant pocket induce a large area of backward escape of lubrication caused by microplasto hydrodynamic lubrication (MPHDL). On the other hand, when the radius on the edge is small MPHDL is impeded and microplasto hydrostatic lubrication appears instead implying forward escape of the lubricant. The occurrence of these mechanisms are quantitatively explained by a mathematical model combining a slab method of analysis of the strip drawing process and an analysis of lubricant escape by Reynolds equation.

Influences of lubricant pocket geometry and working conditions upon micro-lubrication mechanisms in upsetting and strip drawing

Micro-lubricant pockets located in the surface of plastically deforming workpieces are recognised to improve the performance of fluid lubrication in a metal-forming process. This work investigates the joint influence of pocket geometry and process working conditions on micro-lubrication mechanisms, during upsetting and strip drawing, by means of a rigid-viscoplastic finite-element formulation. Special emphasis is placed on the effect of pocket geometry on the build-up of hydrostatic pressure, which is responsible for the onset of micro-lubrication mechanisms. A good agreement is found between the numerically predicted and the experimentally measured distributions of hydrostatic stress.

A quantitative lubricant test for deep drawing

A tribological test for deep drawing has been developed by which the performance of lubricants may be evaluated quantitatively measuring the maximum backstroke force on the punch owing to friction between tool and workpiece surface. The forming force is found not to give useful information regarding the lubricant performance, since it is not sensitive enough to reveal changes in the frictional contact, whereas the backstroke force is very sensitive to pick-up and galling even on micro-scale. Results from testing different lubricants with different performances are found to be consistent with visual judgement of the resulting surface of the drawn cups.

Strategic surface topographies for enhanced lubrication in sheet forming of stainless steel

Strategic stainless steel surfaces have been developed for which the tribological properties are significantly improved for sheet-metal forming compared with the as-received surfaces. The improvements have been achieved by modification of the surface to promote Micro-Plasto Hydrodynamic Lubrication (MPHL) by increasing the ratio of closed lubricant pockets and modifying the pocket geometry. These factors influence the retention and subsequent escape of lubricant during forming thus enhancing lubricant permeability to the contact between flattened workpiece asperities and contacting tool. The technique, which has been developed, is based on an electrochemical treatment changing the topography of the stainless steel surface. Comparative testing of the new surface topographies in ironing and deep drawing of stainless steel sheet shows significant improvements and possibilities of replacing chlorinated paraffin oils with environmentally friendly plain mineral oil.